Customizable modular brush system and method thereof

ABSTRACT

A system and method that utilizes modular components to form a customizable brush for different applications with ease and at a low cost. The system and method utilizes three main components: a base, a plurality of rails, and a plurality of strip brush elements. The plurality of rails is fastened to the base and the plurality of rails holds the strip brush elements to the base to form a brush. All three components may be made of a thermoplastic or thermoset, non-metallic material which can be either rigid or flexible to allow the resulting brush to be easily recyclable.

FIELD OF THE INVENTION

The invention relates to a customizable modular brush system and methodthereof. In particular, a system that utilizes modular components toprovide a customizable brush for different applications with ease and ata low cost.

BACKGROUND OF THE INVENTION

Different types of brushes are utilized in different industries and fordifferent applications. Commercial brushes, such as those for use inconnection with street sweepers, car washes, in-plant sweepers,airports, etc., are highly customized for its specific application.Typically, due to the varied developments over the years of commercialbrushes, brushes used in one industry cannot easily be adapted for usein another industry. Different manufacturers use different machinery toproduce the brushes. Therefore, purchaser of a brush for a particularindustry or application has limited sources. And since a manufacturer isunable to provide brushes to different industries, it cannot readilybenefit from the reduced cost savings resulting from mass production.

Even within an industry, such as street sweeping, different brushes areused. A street sweeper typically has a reusable cylindrical core withreplaceable radiating brush elements attached to the vehicle and areplaceable gutter broom with downward extending brush elements on eachside of the vehicle. While the core with brush elements and gutter broomare normally produced by the same manufacturer, the processes for theirmanufacturing are very different and require separate sets of machineryto produce.

Different industries also use a reusable cylindrical core similar tothose used in street sweepers. For example, airport brush cassettes, carwashes, etc. Currently, such cores are made out of metal. On the outersurface of the core, along the longitudinal axis, is a plurality ofU-shape channels for receiving strips of bristles that are made out ofmetal or plastics. The mixed use of a metal core with either metal orplastic bristles does not allow such brush to be easily recyclable.There are two typical prior art methods of producing these U-shapechannels on the core.

One prior art method is by extrusion, wherein the combined U-shapechannels and core are extruded. See U.S. Pat. No. 6,817,055 to HansEkholm. There are many disadvantages and limitations to this prior artprocess: (1) dies used for the extrusion process is limited in size sothat only certain maximum diameters can be produced; (2) extrudedsections are extremely heavy since the material is thick and isimpossible to reduce the mass by inserting cavities; (3) extremelyexpensive tooling costs, and in most cases, restricted to shapes andsizes for a particular industry or market; (4) extruded metal tends tocure and bend while cooling, requiring the need to rework for dynamicbalancing for high speed usage; (5) extruded U-shape channels must alignwith the axial length of the core; and (6) difficult, if not impossible,to provide different patterns (such as helix, or non-linear) on thecore.

Another prior art method is by welding a U-shape channel onto a core.Each U-shape channel is formed by roll forming a flat metal sheet, thenpinched. There are many disadvantages and limitations to this prior artprocess: (1) dies used for the roll forming of the U-shape channel islimited in size so that only certain maximum diameters can be produced;(2) each U-shape channel has a maximum width before it will not makesufficient contact with the core; (3) extremely expensive tooling costs,and in most cases, restricted to shapes and sizes for a particularindustry or market; (4) if non-corrosive material is needed, expensiveand difficult to work with when welding; (5) requires the use of a largeand expensive spot welding machine to weld the U-shape channels to thecore; (6) axial length of the core is limited to the size of the spotwelding machine; (7) skilled and time intensive labor required to weldthe seams of the U-shape channels every few inches across the entirelength of the core to prevent the U-shape channels from pulling off atthe seam; (8) U-shape channels can only be mounted along the axiallength of the core; and (9) difficult, if not impossible, to providedifferent patterns (such as helix or non-linear) on the core.

Currently the most common process that allows different patterns onbrushes is a staple set machine that staples bristles directly to anon-metallic core. There are many disadvantages and limitations to astaple set brush: (1) the core cannot be efficiently reused since themetal staples must first be removed; (2) core must be of sufficientthickness to support the stapled bristles; (3) the use of a thick coreis costly; and (4) the use of a thick core is heavy, difficult tomanipulate and increases shipping costs.

Therefore, there is a need for an improved brush system that is modularto allow production of customizable brush that can be used in differentindustries and applications with ease, at a low cost and also easilyrecyclable.

SUMMARY OF THE INVENTION

The brush system of the present invention utilizes modular components toproduce a customizable brush with ease and at a low cost. Further, thebrush system of the present invention may be entirely made of plasticmaterial(s) to allow the resulting brush to be easily recyclable. Themethod of the brush system of the present invention can produce brushesfor infinite brush applications. Further, the method of the brush systemof the present invention can produce brushes for all existing industriesand applications.

The brush system utilizes three (3) main components: a base, a pluralityof rails, and a plurality of strip brush elements. The plurality ofrails is attached to the base and the plurality of rails holds the stripbrush elements to the base to form a brush. All three components may bemade of a thermoplastic or thermoset, non-metallic material which can beeither rigid or flexible.

The base can be of various shapes, such as tubular, prism, flat,arcuate, etc., and have various cross-sections, such as rectangular,circular, etc. Optionally, a plurality of grooves is provided on thebase to receive the plurality of rails to provide increased contactsurfaces between the base and the rails. The grooves may take on variousforms, such as linear, curved or any other desirable configuration orpattern, and may have various cross-sectional shapes. The density andpattern of the grooves can be easily formed depending on the intendedapplication of the resulting brush.

Each rail is elongated and has a cross section that has a generallywider upper profile and a generally narrower lower profile such asT-shape, U-shape with overhanging ends, upside down Ω-shape, etc. Thelower portion of the rail is fastened onto the surface of the base or,optionally into the grooves, by adhesive, epoxy, mechanical fastening,chemical fastening, sonic fastening or fusion fastening. The rails canbe configured and fastened to the base with various density and patternor can be configured to take on the configuration or pattern of thegrooves. Adjacent rails form a channel having a cross-section with anarrower upper profile and a wider lower profile for receiving andsecuring a strip brush element onto the base. The width of the channelscan vary depending on the distance between adjacent rails. Optionally,the base and rails are formed integrally by milling the channels into athicker base.

Each strip brush element has a coupling end and at least one brushelement extending therefrom. The brush element can be in the form ofbristles, tufts of bristles, baffle strip, stripping, etc. and made ofmetal, felt, thermoplastic, thermoset, micro fiber, or other flexiblematerial, etc. The cross section of the coupling end has a wider profilethan the brush element profile such that the strip brush element isreceived and secured in the channel formed between adjacent rails. Thecoupling end of the strip brush element can have different widths forsecured receipt in the channels. A narrower or flexible coupling endprovides the flexibility to conform to curved, or other patterned,channels. After sliding the strip brush element into and between thechannels, a holder can be mounted onto the base or the rails to preventthe strip brush element from sliding out of the rails.

The use of thermoplastic or thermoset material in the brush system ofthe present invention allows efficient, quick and easy customization ofeach modular component at a low cost, with the resulting brush beingeasily recyclable, and even possibly bio-degradable. The density andpattern of the resulting brush can be customized by manipulating thewidth, density and pattern of the rails and strip brush elements.Different types of brushes for use in different industries and differentapplications can be produced with different sizes and shapes bases.There is no limitation on the size or shape of the resulting brush.There is minimal tooling cost and there is no need to use highly skilledwelding professionals in connection with the brush system of the presentinvention. A customized brush of the present invention can easily beproduced as by a mass production. Small quantities of unique brushes canbe easily fabricated with simple fabrication equipments and minimallyskilled laborer.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the present invention have been chosen forpurposes of illustration and description and are shown in theaccompanying drawings forming a part of the specification wherein:

FIG. 1 is a side view of the brush of the present invention having aplanar rectangular base with longitudinal rails.

FIG. 2 is a top view of the base and rails of FIG. 1.

FIG. 3 is a front view of the brush of FIG. 1.

FIGS. 4A-4C illustrate cross-sections of different grooves.

FIG. 5 is a side view of another embodiment of the brush of the presentinvention similar to FIG. 1 but with integral rails.

FIG. 6 is a side view of another embodiment of the brush of the presentinvention similar to FIG. 1 but with curved rails.

FIG. 7 is a top view of the base and rails of FIG. 6.

FIGS. 8A-8D illustrate different channel patterns on a planar base.

FIGS. 9A-9F illustrate different planar shape base.

FIG. 10 is a side view of another embodiment of the brush of the presentinvention having a tubular base.

FIG. 11 is a perspective view of FIG. 10.

FIGS. 12A-12D illustrate different channel patterns on a tubular base.

FIG. 13 is a perspective view of another embodiment of the brush of thepresent invention having two corresponding arcuate bases.

FIG. 14 is a side view of FIG. 13.

FIGS. 15A-15B illustrate different channel patterns.

FIG. 16 is a side view of another embodiment of the brush of the presentinvention having a second set of brush elements.

FIG. 17 is a side view of another embodiment of the brush of the presentinvention similar to FIG. 10 but with integral rails.

FIG. 18 is a side view of FIG. 17, without the strip brush elements.

FIG. 19 is a side view of another strip brush element of the presentinvention.

FIG. 20 is a side view of another embodiment of the brush of the presentinvention similar to FIG. 10 but having a support element for thebristles.

FIG. 21A-21B show the partial side and top views of another embodimentof the brush of the present invention similar to FIG. 10 but thecoupling end of the strip brush element having a feather board side.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

With reference to the drawings, wherein the same reference numberindicates the same element throughout, there is shown in FIGS. 1-3 abrush 100 of the present invention. The brush 100 comprises a base 110,a plurality of rails 140 and a plurality of strip brush elements 170,all of which may be made of a thermoplastic or thermoset material. Eachof these components, base 110, rail 140 and strip brush element 170, maybe extruded, molded, or otherwise produced by methods known to oneskilled in the art.

As shown in FIGS. 1-3, base 110 has a planar rectangular shape with aplurality of spaced apart and longitudinal grooves 112 on its surface.Grooves 112 are formed on the base 110 by cutting, carving, grounding,etching or milling. The density of the grooves 112 can be customized tothe specific application or use. A plurality of elongated rails 140 arefastened, spaced apart and longitudinally, in the grooves 112 of thebase 100 by means known to one skilled in the art, but possibly withoutthe use of metal parts.

The surfaces of the grooves 112 can be roughed up to further improve thecontact and fastening with the rails 140. While grooves 112 is shown inFIGS. 1-3 to be linear and having a rectangular cross section, thegrooves 112 may be curved or any other desirable configuration orpattern and may have various cross-sectional shapes such as thosegrooves 112 a-112 c shown in FIGS. 4A-C. The grooves 112 a-112 c havingvarious cross-sectional shapes shown in FIGS. 4A-4C further improve thecontact and fastening with the rails 140.

As shown in FIG. 1, each rail 140 is elongated and has a cross sectionthat is generally T-shape. Rails with other cross-sectional shapes, suchas U-shape with overhanging ends, upside down Q-shape, having an upperportion 142 with a wider profile than a lower portion 144 with anarrower profile can also be used. The T-shape rail 140 as shown in FIG.1 has a mid portion 143 with a tapered profile, which is optional. Thelower portion 144 is shown to correspond and fit snuggly in the groove112. For grooves 112 a-112 c as shown in FIGS. 4A-4C, the lower portions144 a-144 c are correspondingly shaped to fit within the grooves. Forgroove 112 b, the lower portion 144 b may be longitudinally slid into itfor fastening. For groove 112 c, the lower portion 144 c may be snappedinto it for fastening. The lower portion 144 may also be tapered, ornotched (not shown) to provide additional spacing between the rail 144and the groove 112 to allow adhesive to set in between for improvedfastening. Further, the lower portion 144 may have a latch extension(not shown) that cooperates with an opening on the base 100 foradditional support and secured attachment. While the grooves 112 areshown on the base 110, the rails 140 can also be fastened directly ontothe surface of the base 110. Adjacent rails 140 form a channel 146therebetween with an upper space 148 having a narrower profile and alower space 150 having a wider profile. Optionally, the channel 146 hasa mid space 149 having the widest profile. The width of the channel 146can vary depending on the distance between adjacent rails 140, which canbe easily customizable.

As shown in FIG. 1, each strip brush element 170 is elongated with acoupling end 172 with a brush element 174 extending therefrom, generallyknown to one skilled in the art. A prior art strip brush element 170that may be modified and used in connection with the present inventionis disclosed in U.S. Pat. No. 5,819,357 to Frances Gould (which isinserted into a metal drum). Other prior art strip brush element mayalso be adapted to be used with the present invention. As shown in FIGS.1 and 3, the brush element 174 is shown to be a continuous row ofbristles. The brush element 174 can be made from a variety of materialsgenerally known to one skilled in the art. The cross section of thecoupling end 172 corresponds to the cross sectional profile of thechannel 146 such that the coupling end 172 can slidably and frictionallyfit in the channel 146 to be held in position by adjacent rails 140. Asshown in FIG. 1, the cross sectional profile of the coupling end 172 hasa narrowest upper section 172A and a widest mid section 172B to becorrespondingly secured by the upper portion 142, and mid and lowerportions 143 and 144, of the rail 140, respectively. The use ofthermoplastic or thermoset provides a low coefficient of friction forthe base 110, rails 140 and strip brush elements 170 such that the stripbrush elements 170 can fit tightly (with little tolerance) in thechannels 146 to reduce rocking when the brush 100 is being used. Theprior art brush's use of different materials (such as metal and plastic)for different portions of the brush disadvantageously allows morerocking, which in the long run can damage both the brush and the drivingmechanism. The coupling end 172 can have different widths for securedreceipt in the channels 146. While FIG. 1 shows a strip brush element170 in each channel 146, further customization can be accomplished byselectively positioning strip brush element 170 in only certain, but notall, channels 146. Similarly, while FIG. 1 shows a strip brush element170 extending across the full length of the channel 146, furthercustomization can be accomplished by using shorter strip brush element170 discretely positioned along the channels 146. Brush 100 may havebrush elements 174 made out of the same or different materials,depending on the application. The strip brush elements 174 are preventedfrom sliding out of the channels 146 by providing a holder (not shown)that can be attached to the base 110 or the rails 140, whether on theplanar surface or on the sides of the base 110.

Brush 100 can be customized by the selective positioning of the grooves112 and/or rails 140 and the spaces between adjacent rails 140. Thewidths of the rails 140 and the coupling ends 172 of the strip brushelements 170 can vary for further customization. Brush elements 174 madeof different materials can be selectively inserted in the channels 146for additional customization.

The method of producing a customizable brush of the present invention,such as brush 100, requires a base 110 of any shape or size, a pluralityof elongated rails 140 of any width and length, and a plurality of stripbrush elements 170 of any width and length. A plurality of grooves 112,of any desirable pattern, may optionally be cut on the surface of thebase 110. The rails 140 are fastened either directly on the surface ofthe base 100 or in the grooves 112. The rails 140 are fastened to thebase to produce any desirable pattern. A strip brush element 170 is theninserted between adjacent rails 140 to form a customized brush.

FIG. 5 shows a brush 200 similar to brush 100 of FIGS. 1-3. The top andfront views of the brush 200 are the same as FIGS. 2-3. The differencebetween the brush 200 and brush 100 is that the rails 240 are formedintegrally with the base 210. The integral rails 240, and thecorresponding channels 246, are formed by cutting, carving, grounding,etching or milling into a planar rectangular base 210 that is thickerthan the base 110. The strip brush elements 170 are then slidablysecured in the channels 246.

FIGS. 6 and 7 show a brush 300 similar to brush 200 of FIG. 5. The frontview of the brush 300 is the same as FIG. 3. The difference between thebrush 300 and brush 200 is that the integral rails 340, and thecorresponding channels 346, are curved. Such curved channels 346 aredifficult, if not impossible, to produce with any prior art method.While the rails 340 are shown to be integral with the base 310, therails 340 can be fastened to the base 310 as discussed in connectionwith brush 100 of FIGS. 1-3. To facilitate the slidable insertion of thestrip brush element 370 into the curved channels 346, the coupling end372 of the strip brush element 370 is narrow or flexible.

The brushes 100, 200 and 300 as shown in FIGS. 1-3 and 4-6 are ideally,but not limited to be, used as sweep-backs for use with forklifts. Brush300 having curved rails 340 and corresponding curved channels 346 aidsin the guiding of debris during sweeping. Other channel patterns, notlimited to those illustrated in FIGS. 8A-8D, can be used for the brushof the present invention. The densities and widths of the channel shownin FIGS. 8A-8D can be customized. While the brushes 100, 200 and 300 ofFIGS. 1-3 and 4-6 each has a planar rectangular base 110, 210 and 310,different shapes planar base, not limited to those illustrated in FIGS.9A-9E, can also be used. The channel patterns shown in FIGS. 9A-9F aremerely for illustration only and other channel patterns can be used inthose bases. FIG. 9F illustrates a base formed from two identical partsthat are put together after the strip brush elements 170 are insertedbetween adjacent rails 140.

FIGS. 10-11 show a brush 400 having a tubular base 410 with a pluralityof spaced apart and longitudinal grooves 412 on its surface. Similar tothe brush 100, fastened to the grooves 412 are a plurality of rails 140;adjacent rails 140 define a channel 146; and a strip brush element 170is slidably received in each channel 146. Similar to the brush 200,rails 140 can also be integrally formed from the base 410 using athicker tubular base 410. Different channel patterns, not limited tothose illustrated in FIGS. 12A-12D, can also be used on the tubular base410.

FIGS. 13 and 14 show a brush 500 having a tubular base 510 formed fromtwo corresponding arcuate bases 512 a and 512 b. Fastened to eacharcuate base 512 is a plurality of semi-circular rails 540 definingsemi-circular channels 546 therebetween for receiving strip brushelements 170. A plurality of grooves 512 may be provided on the surfaceof the arcuate base 512 to receive the rails 540. To assemble brush 500from the components, each arcuate base 512 are first fastened withsemi-circular rails 540, then strip brush elements 170 are then slidablyinserted into the channels 546. Once each arcuate base 512 is filledwith the strip brush elements 170, the two arcuate base 512 a and 512 bare then interconnected to form a tubular base. The interconnection ofthe arcuate bases 512 a and 512 b is shown in FIG. 14 as a tongue andgroove combination, but other methods of interconnection known to oneskilled in the art can also be used. The resulting brush 500 hascircular strip brush elements 170 around the circumference of thetubular base, similar to a wafer broom. The configuration of brush 500is not achievable with the prior art processes of extrusion or weldingof the channels. While brush 500 is shown to have circular strip brushelements 170, the rails 540 and corresponding channels 546 may be at anangle such that the strip brush elements 170 form an oval or ellipticalshape (not shown). Further, as illustrated in FIG. 15A the channels 546can form a continuous helical pattern or as illustrated in FIG. 15B, thechannels 546 of FIG. 15A can be offset so that they do not form acontinuous helical pattern.

FIG. 16 shows a brush 600 similar to brush 400 of FIGS. 10-11, exceptthat there is a second set of brush elements 676 extending from theupper surface of each rail 640. The resulting brush 600 provides twicethe density of brush elements of brush 400. The brush elements 174 ofthe strip brush element 170 between adjacent rails 640 and the secondset of brush elements 676 may be made of the same or differentmaterials, depending on the specific application of brush 600. Insteadof having the second set of brush elements 676 extending directly fromthe rails 640 as shown in FIG. 16, each rail 640 can alternatively havean elongated canal (not shown) on the upper surface for receiving astrip brush element 170.

FIGS. 17 and 18 show a brush 700 similar to brush 400 of FIGS. 10-11,except that brush 700 has integral rails 740. Rails 740 are formedintegrally with tubular base 710 by cutting, carving, grounding, etchingor milling a plurality of channels 746 on the surface of a tubular base710 that is thicker than the base 410. The channels 746 can tightlyconform to the shape of the coupling end 172 of a strip brush element170 to minimum rocking of the strip brush element 170 during use.

FIG. 19 shows another embodiment of the strip brush element 270 that canbe used in connection with any base and rail described herein. Similarto strip brush element 170, strip brush element 270 has a coupling end272 and a brush element 274 extending therefrom. The upper portion ofthe coupling end 272 has stabilizing lip 276 that overlay the upperportion of the rail 240 to stabilize, and to minimizing rocking of, thestrip brush element 270 when in use.

FIG. 20 shows a brush 800 similar to brush 400 of FIG. 10, except thatbrush 800 has a support element 840 extending radially away from thetubular base 410 from the top of the rail 140. The support element 840has a generally triangular prism shape that extends longitudinally alongand on the rail 140. The support element 840 can be made of the samematerial as the remaining components of the brush 800, be integrallyextruded along with the rail 140 or be removably attachable to the rail140. The unique shape of the support element 840 provides contact withthe brush element 174, and thereby supports the brush element 174, at apoint other than the coupling end 172 of the strip brush element 170. Asa result, when brush 800 is rotated in the direction A, the brushelement 174 as supported by the support element 840 changes the stresspoint of the brush element 174 to produce a different brush action thana brush element 174 without the support element 840 (as in brush 400 ofFIG. 10). Further, brush 800 can use finer (smaller diameter) brushelement 174 to result in the same strength as a wider diameter brushelement 174 used in brush 400 of FIG. 10 while using less material andhaving the sweeping attribute of a finer brush element 174. The supportelement 840 may have a different shape than the generally triangularprism shape as shown as long as it provides contact and support to thebrush element 174 at a point higher than the coupling end 172 of thestrip brush element 170. Further, the support element 840 may not becontinuous longitudinally and may be a plurality of discrete elementsspaced apart along the longitudinal length of the rail 140 to provide adifferent brush action. Instead of being similar to brush 400 of FIG.10, brush 800 can be similar to brush 700 of FIGS. 17 and 18, with thesupport element 840 integrally formed from milling the channels andsupport elements from a thicker base.

FIG. 21A-21B show the partial side and top views of a brush 900 similarto brush 400 of FIG. 10, with the mid section 972B of the coupling end972 of the strip brush element 970 formed from a plurality of fingers973 to allow one way insertion of the strip brush element 970 into thechannel 146. As shown, one side of the mid section 972B of the couplingend 972 of the strip brush element 970 has a plurality of fingers 973disposed at an angle to form a feather board. The width of the midsection 972 b is slightly wider than the mid space 149 of channel 146such that the strip brush element 970 is inserted into the channel 146in one direction only (direction B). The fingers 973 compress slightlyinto the mid space 149 for insertion and for a snug and frictional holdin the channel 146, which prevent movement of the strip brush element970 in the opposite direction. Mid portion 143 of the rail 140 adjacentthe fingers 973 may have spaced-part bumps thereon to further preventthe movement of the strip brush element 970 in the opposition direction.While FIGS. 21A-21B show that one side of the mid section 972B hasfingers 973, both sides of the mid section 972B can optionally havefingers 973. Further, instead of having the fingers 973 in the midsection 972B of the strip brush element 970, the fingers may extend fromthe mid portion 143 of the rails to produce the same result. The fingers973, whether on the strip brush element 970 or rail 140, can be producedafter the strip brush element 970 or rail 140 is extruded and passing itthrough a gear wheel, etc. to produce the fingers 973.

In the discussion of the various embodiments above, the strip brushelements 170 is slidably insertable longitudinally into the channels 146between adjacent rails 140. The strip brush element 170 may also besnapped into the channel 146, in a side-by-side fashion, if alternatingrails 140 having different rigidities are provided. For example, onerail 140 can be made out of a rigid material and the adjacent rail 140be made out of a flexible material such that one side of the couplingend 172 of the strip brush element 170 is first inserted into the rigidrail 140 and then the other side of the coupling end 172 is forced pastthe flexible rail 140 for complete insertion of the coupling end 172into the channel 146.

One of the advantages of the brush system of the present invention isthe efficiency and ease in producing a customized brush. There is noneed for highly skilled welding professionals, and the process offastening the rails to the base can be easily accomplished by anon-skilled laborer. A method of fastening the rails to the base is byapplying adhesive to the lower portion of the rail and then placing therails on the surface of the base; the rails can be held in place eithermanually or with a clamp until the adhesive is set. Additional fastenerssuch as screws, rivets, nuts and bolts, can be used to ensure secureattachment. Such efficiency and ease similarly extends to the repair ofthe customized brush. The most common place for failure, due to fatigueor misuse, of a prior art brush is the detachment of the U-shapechannels from the base. If similar failure occurs with the brush of thepresent invention, the rails can easily be re-fastened, e.g. byadhesive, to the base to allow the brush to function once again.

Another advantage of the brush system of the present invention is theability to custom design a brush to create a more efficient sweepingpattern (or other desired effects such as brushing, deflecting, mopping,or acts as a spray suppressant) for various applications.

Another advantage of the brush system of the present invention is theability to produce a brush entirely made of thermoplastic or thermoset.Further, such brush may be entirely recyclable. Such brush also lendsitself to certain applications of the brush in a wet environment becausethere is no metal part that may rust. This is an especially importantaspect for a brush being used in an underwater (fresh or salt water)environment where typically expensive stainless or aluminum prior artbrush is required. The use of thermoplastic or thermoset material alsofacilitates the addition of different additives to the plastic to changeeither the material composition or to add color for identificationpurposes. In a prior art brush, a completely separate set up is requiredto paint the brush different colors.

Another advantage of the brush system of the present invention is theability to customize a base with rails that is reusable with thereplacement of the strip brush elements as they are worn out from use.Further, the customized base with rails can replicate all existingbrushes in all industries and applications. Still further, the base withrails can advantageously be customized to accept or receive existingstrip brush elements.

The features of the invention illustrated and described herein are thepreferred embodiments. Therefore, it is understood that the appendedclaims are intended to cover the variations disclosed and unforeseeableembodiments with insubstantial differences that are within the spirit ofthe claims.

1. A method of producing a brush from modular components, comprising thesteps of: providing a base having a surface; providing at least twoadjacent elongated rails, each rail having a cross section with a widerupper portion and a narrower lower portion; fastening each said rail onsaid surface of said base predeterminedly spaced apart from each other,wherein said adjacent rails defining a channel having a cross sectionwith a narrower upper space and a wider lower space; providing at leastone elongated strip brush element having a coupling end and a first setof brush element extending from said coupling end, said coupling endhaving a cross section with a narrower upper section and a wider lowersection corresponding to said narrower upper space and wider lowerspace, respectively, of said channel; and slidably inserting saidcoupling end of said strip brush element in said channel to be removablyheld therein abutting said surface of said base.
 2. The method of claim1 wherein said rails are linearly fastened to said surface of said baseto define linear channels.
 3. The method of claim 1 wherein said railsare non-linearly fastened to said surface of said base to definenon-linear channels.
 4. The method of claim 1 further comprising thestep of providing at least two adjacent grooves on said surface of saidbase for receiving said rails such that said rails are fastened intosaid grooves on said surface of said base.
 5. The method of claim 4wherein each said groove having a cross section corresponds with thecross section of said narrower lower portion of each said rail.
 6. Themethod of claim 1 wherein said fastening is accomplished with anadhesive.
 7. The method of claim 1 wherein said fastening isaccomplished with fusion.
 8. The method of claim 1 further comprisingthe step of providing means for holding said strip brush element in saidchannel.
 9. The method of claim 1 wherein said surface of said base isplanar.
 10. The method of claim 1 wherein said surface of said base isnon-planar.
 11. The method of claim 1 providing a plurality of rails anda plurality of strip brush elements, further comprising the step offorming a predetermined pattern on said surface of said base from saidplurality of rails and said plurality of strip brush elements.
 12. Themethod of claim 1 wherein said base, rails and strip brush elements aremade of a thermoplastic material.
 13. The method of claim 1 wherein saidbase, rails and strip brush elements are made of a thermoset material.14. The method of claim 1 wherein said base, rails and strip brushelements are made of a non-corrosive material.
 15. The method of claim 1wherein said base is formed from two corresponding parts.
 16. The methodof claim 1 wherein each said rail having an upper surface, furthercomprising the step of providing a second set of brush element extendingfrom said upper surface of each said rail.
 17. The method of claim 1wherein each said rail having an upper surface, further comprising thestep of providing a stabilizing lip extending from said upper section ofsaid coupling end such that said stabilizing lip overlay said uppersurface of said rail.
 18. The method of claim 1 further comprising thestep of providing a plurality of fingers at said coupling end such thatsaid coupling end is slidably insertable into said channel in onedirection only.
 19. The method of claim 1 providing a plurality ofrails, wherein alternating rails are made of a rigid thermoplasticmaterial and a flexible thermosplastic material.
 20. The method of claim1 providing a plurality of rails, wherein alternating rails are made ofa rigid thermoset material and a flexible thermoset material.
 21. Themethod of claim 1 further comprising the step of providing a supportelement extending from said upper portion of said rail such that saidsupport element is in contact with said first set of brush element. 22.A brush prepared by a process comprising the steps of: providing a basehaving a surface; providing at least two adjacent elongated rails, eachrail having a cross section with a wider upper portion and a narrowerlower portion; fastening each said rail on said surface of said basepredeterminedly spaced apart from each other, wherein said adjacentrails defining a channel having a cross section with a narrower upperspace and a wider lower space; providing at least one elongated stripbrush element having a coupling end and a first set of brush elementextending from said coupling end, said coupling end having a crosssection with a narrower upper section and a wider lower sectioncorresponding to said narrower upper space and wider lower space,respectively, of said channel; and slidably inserting said coupling endof said strip brush element in said channel to be removably held thereinabutting said surface of said base.
 23. A method of producing a brushfrom modular components, comprising the steps of: providing a basehaving a surface; milling at least one elongated channel on saidsurface, each said channel having a cross section with a narrower upperspace and a wider lower space; providing at least one elongated stripbrush element having a coupling end and a first set of brush elementextending from said coupling end, said coupling end having a crosssection with a narrower upper section and a wider lower sectioncorresponding to said narrower upper space and wider lower space,respectively, of said channel; and slidably inserting said coupling endof said strip brush element in said channel to be removably heldtherein.
 24. The method of claim 23 wherein said channels are linear.25. The method of claim 23 wherein said channels are non-linear.
 26. Themethod of claim 23 further comprising the step of providing means forholding said strip brush element in said channel.
 27. The method ofclaim 23 wherein said surface of said base is planar.
 28. The method ofclaim 23 wherein said surface of said base is non-planar.
 29. The methodof claim 23 providing a plurality of channels and a plurality of stripbrush elements, further comprising the step of forming a predeterminedpattern on said surface of said base from said plurality of channels andsaid plurality of strip brush elements.
 30. The method of claim 23wherein said base and strip brush elements are made of a thermoplasticmaterial.
 31. The method of claim 23 wherein said base and strip brushelements are made of a thermoset material.
 32. The method of claim 23,wherein said base and strip brush elements are made of a non-corrosivematerial.
 33. The method of claim 23 wherein said base is formed fromtwo corresponding parts.
 34. The method of claim 23 providing aplurality of channels, further comprising the step of providing a secondset of brush element extending from said surface of said base betweenadjacent channels.
 35. The method of claim 23 further comprising thestep of providing a stabilizing lip extending from said upper section ofsaid coupling end such that said stabilizing lip overlay said surface ofsaid base.
 36. The method of claim 23 further comprising the step ofproviding a plurality of fingers at said coupling end such that saidcoupling end is slidably insertable into said channel in one directiononly.
 37. The method of claim 23 further comprising the step of millingat least one support element between adjacent channels such that saidsupport element is in contact with said first set of brush element. 38.A brush prepared by a process comprising the steps of: providing a basehaving a surface; milling at least one elongated channel on saidsurface, each said channel having a cross section with a narrower upperspace and a wider lower space; providing at least one elongated stripbrush element having a coupling end and a first set of brush elementextending from said coupling end, said coupling end having a crosssection with a narrower upper section and a wider lower sectioncorresponding to said narrower upper space and wider lower space,respectively, of said channel; and slidably inserting said coupling endof said strip brush element in said channel to be removably heldtherein.
 39. A modular brush system, comprising: a base having asurface; at least two adjacent elongated rails fastened to said surfaceof said base defining a channel between said adjacent rails, each saidrail having a cross section with a wider upper portion and a narrowerlower portion, and said channel having a cross section with a narrowerupper space and a wider lower space; and at least one elongated stripbrush element having a coupling end and a first set of brush elementextending from said coupling end, said coupling end having a crosssection with a narrower upper section and a wider lower sectioncorresponding to said narrower upper space and wider lower space,respectively, of said channel to be removably held within said channelabutting said surface; wherein said base, said rails and said elongatedstrip brush elements are made of a thermoplastic material.
 40. Themodular brush system of 39, wherein some of said base, rails andelongated strip brush elements are made of a rigid thermoplasticmaterial.
 41. A modular brush system, comprising: a base having asurface; at least two adjacent elongated rails fastened to said surfaceof said base defining a channel between said adjacent rails, each saidrail having a cross section with a wider upper portion and a narrowerlower portion, and said channel having a cross section with a narrowerupper space and a wider lower space; and at least one elongated stripbrush element having a coupling end and a first set of brush elementextending from said coupling end, said coupling end having a crosssection with a narrower upper section and a wider lower sectioncorresponding to said narrower upper space and wider lower space,respectively, of said channel to be removably held within said channelabutting said surface; wherein said base, said rails and said elongatedstrip brush elements are made of a thermoset material.
 42. The modularbrush system of 41, wherein some of said base, rails and elongated stripbrush elements are made of a rigid thermoset material.